Method for forming and assembling inner spring constructions



y gg v E, E. WOLLER METHOD FOR FORMING AND ASSEMBLING INNER SPRING CONSTRUCTIONS Originl Filed Sept. 7, 1942 4 Sheets-Sheet 1 y 1947- E. E. WOLLER 2,420,512

METHOD FOR FORMING AND ASSEMBLING INNER SPRING CONSTRUCTIONS Original Filed Sept. 7, 1942 4 Sheets-Sheet 2 Jgyfa Ma 13, 1947. E E, WOLLER v 2,420,512

METHOD FOR FORMING AND ASSEMBLING INNER SPRING CONSTRUCTIONS Original Filed Sept. 7, 1942 4 Sheets-Sheet 3 May 13,1947.

E. E. WOLLER METHOD FOR FORMING AND ASSEMBLING INNER SRING CONSTRUCTIONS Original Filed Sept. 7', 1942 was Fi i 5m 4 Sheets-Sheet 4 .ZZ/ward'f Mal /e7 Patented May 13, 1947 UNITED STATE 5 PATENT, OFFICE METHOD FOR FORIVIING AND ASSEMBLING INNER SPRING CONSTRUCTIONS Edward E. Woller, Kenosha, Wis., assignor to Simmons Company, a corporation of Delaware Original .applicatlon September No. 457,584; now Patent No.

7, 1942, Serial 2,388,106, dated October 30, 1945. Divided and this application March 27, 1944, Serial No. 528,242

sembling coil'springs and uniting rows thereof by means of wire helices fed endwise and rol0 tated and guided so as to be threaded around juxtaposed coil portions of the springs. In the machines heretofore devised, the coil springs were preformed and the coil portions thereof which are embraced by the tying helix may be straightened out somewhat to facilitate threading of the helix therearound,. the straightened coil-portions being thereafter permitted to return to approximately normal position. The return of the straightened coil portions to approximately normal condition results in a desirable binding effect'which prevents the production of rattling noises in the spring construction incident to relative moving of the spring coils and helices.

Spring constructions have also been made wherein the springs have their end coils preformed with specially shaped offsets which more or less interflt when the springs are arrangedin rows, the offsets sometimes being disposed substantially in contact with each other and sometimes in relatively oflset relation, the usual wireh'elices being employed to unite such preformed spring coil portions.

The present invention has for its main ob 'ect the provision of a method for forming and assembling inner spring constructions wherein the springs are provided with offsets around which a wire helix is threaded for uniting the springs, and in which method the spring oflfsets are formed in the springs as an incident to, or as a part of thejoperation of assembling and holding the --siivrings in the predetermined position in which they are to be united by the wire helix;

Other objects of the invention new provide a. method of the character indicated which will be operative at fairly high speed so as to provide an adequate rate of inner spring unit production; to provide a method of the character indicated which,.will be automatic in operation and will not requir manual handling or operations; and in general it is the object of the invention to provide. an improved method of the character indicated.

Other objects and advantages of the invention will be understoodby reference to the fol- 5 Claims. (Cl. 140-3) lowing specification and accompanying drawings (four sheets) wherein there is disclosed the improved method and apparatus for the production or two forms of coil offsets together with certain elements of mechanism for holding the springs with their offsets in juxtaposed positions and means for guiding a helical wire around the coil I offsets.

Inthe drawings: I

Fig. 1 is a fragmentary plan. Fig.2 is a section on the line 2-2 of Fig. 1. Fig. 3 is a section on the line 3-4 of Fig. 1. Fig. 4 is a section onthe line 4-4 of Fig. 3. Fig. 5is a. plan of one element of mechanism appearing in the other figures and illustrating certain details thereof. i

Fig. 6 is a fragmentary plan view corresponding .to Figure 1 but showing a modified arrangement.

20 Figs. 7 and 8 are sections respectively on the lines 1-1 and H of Figure 6.

Fig. 9 is an end elevation of the spring coil forming and gripping end of one of a pair of cooperating jaws, the location of this view bein substantially as indicated by the line 9-9 of Figure '7.

Fig. 101s a fragmentary plan 'of one element of mechanism appearing in the '-construction shown in Figures 8 to 8 and in Figure 11.

Fig. 11 is a fragmentary plan section approximately on the plane indicated by the line Il'-ll of Fig. 7.

The mechanism herein disclosed is adapted to be employed in apparatus such as shown in Pat. ent No.v 1,905,459 to Gail and in Patent No. 2,388,106 to me. In the mechanism herein disclosed certain jaw parts are movabletoward and from each other and toward and from a guide track substantially as are counterparts of the mechanism shown in the said patents. Reference'is therefore made to said patents for a complete disclosure of the mechanism for actuating. the parts of the mechanism herein disclosed. I

Referring first to Figures 1 to 5 inclusive, there is there shown mechanism including a pair of jaws l2 and i3, for sliding movement toward and from each other on a bed plate ll mounted'on a suitable supporting frame structure IS. The jaw I2 is adapted to be reciprocated in an endwise direction by means of .a rock arm I 8 pivotally mounted intermediate its ends as indicated at I! to a bracket carried by the frame It. The law I! the same being suitably mounted IS on a suitable bracket carried by the frame I5. The arms I6 and I8 have their lower ends (not shown) suitably connected to mechanism for rocking the arms and the upper ends of the arms are equipped with anti-friction rollers disposed in suitable recesses or openings in the jaws l2 and I3 for transmitting rocking movement of the upper ends of said arms into slidin movement of the respective jaws. The arms I6 and, I8 are so actuated that the jaws I2 and I3 simultaneously move toward each other and later away from each other.

The relatively adjacent ends of the jaws I2 and I3 also cooperate with a guide track 20 which is suitably mounted in the bed plate I4 or other supporting parts, preferably as shown in my said co-pending application. The guide track 20 consists of a series of sections such as shown in Figure 1, the sections being arranged end to'end to form a continuous, elongated track extending for the full length of rows of coil springs'which are to be united by wire helices.

The track section 20 associated with each pair of Jaws is provided adjacent the opposite sides of the jaws with upstanding flange elements 2|, 22, 23, and 24 which cooperate with the track element 20 to form a channel structure of substantially the same depth as the outside diameter of the helix employed, one of which is illustrated at 25. a Coil springs indicated 28 and 21 respectively each represent one spring of a row of such springs which are to be joined by a helix such as 25. The coil springs, when delivered to the apparatus, are of normal, approximately circular formation.

The jaw I3 ha its operative end shap d to substantially correspond to the interior of an ofiset to be formed in the terminal coil of the spring 21. The track element 20 is provided with a recess 28 of'a depth substantially corresponding to the thickness or diameter 01. the wire in the coil spring 21. Said recess is shaped to cooperate with the operative end portion I 3a of the jaw I3 to form an offset having an initially straightened portion 29 and end portions 30-30 making the elongated straightened portion 23 in the coil body proper (see Figure 4). As best shown in Figure 4, the flange elements 22 and 24 of the guide track structure have their ends so shaped as to constitute continuations of the shoulder or recess 28 in the track bar 20 for also cooperating with the adjacent end portion of the jaw I3 to form said ofiset.

The jaw I3 is also preferably provided with ear portions 3I-3I on its opposite sides for engaging the spring coil 21 to bend the same around the adjacent rounded corner portions of the guide track flanges 22 and 24. Said ear portions 3| are preferably recessed as indicated at 32 to receive the adjacent portions of the coil 21 so as -toprevent lateral displacement thereof incident to the forming pressure-developed in the operation of the jaw. M

The jaw I2 similarly has its operative end provided with a seat 33 having rounded receding end portions 3434 for bending a part of the terminal coil of the spring 26 to substantially straight form indicated at 35 but without forming any permanentor sharp bends or end shoulders or legs such as the shoulders 30 formed in the spring coil 21. The rounded end portions 34 of the seat in the jaw I2 cooperates with suitably chamfered corners 35 of the helix guide track flange elements 2I and 23. The seat portion 33 of the jaw I2 cooperates also with a correspondingly formed shoulder portion 36 of the jaw I3 (see Figure 3) to grip and hold the straightened coil portion 35 in its straightened position substantially overlying the straightened offset portion 3| of the coil 21. The jaw I2 also is provided with a lip portion 31 which, as shown in Figure 3, extends over the uppermost coil portion 35 so that the jaw I2 cooperates with the jaw I3 and with the track 20 to completely enclose said coil portions 29 and 35.

The track 20 is provided with helically disposed grooves 38 correspondin to the pitch and lead of the helix 25 and the adjacent or cooperating ends of the jaws I2 and I3 are also provided with grooves I217 and I3!) respectively which constitute, in effect, continuations of the grooves 38. The grooves in the ends of the jaws and the grooves in the track 20 serve to permit the helix 25 to be rotated and fed endwise between the jaws while said jaws are cooperating to hold the springs 26 and 21 with the offset and flattened portions formed therein substantially as shown in Figure 4. When the helix is so guid-. ed and led endwise, it will of course be wound around the juxtaposed spring coil portions 29 and 35.

When the jaws I2 and I3 are opened up or moved from each other and from the track 20, the inherent resiliency of the spring wire employed in the coils 26 and 21 will cause the flattened and ofiset coil portions 35 and 29 to resume a more or less arched formation as illustrated at the righthand end 01' Figure 1. Such return to arcuate form from the straightened form produced by the laws is desirable in that it tends to create pressure points between the spring coil portions and the helix 25 which prevent relative shifting and incidental rattling noises in the spring construction unit. The extent to which the flattened portions will return to arcuate form depends of course somewhat upon the resiliency of the wire employed in making the springs. Some control of the final form of the offsets is possible by appropriately shaping the cooperating ends of the jaws within limits dictated by the requirements of effecting sufi'icient straightening of the coil portions to insure free travel of the helix around the same.

In the arrangement shown in Figures 6 to 11 inclusive the terminal coils of springs designated 40 and 4! respectively have relatively short off, sets 42 and 43 respectively formed therein and held in longitudinal, substantially co-axial alinement while a wire helix 44 is threaded around the same. The wire helix .44 is guided by a. suitably grooved track section 45 which substantially corresponds to the track section 20 shown in Figures 1 to 5 inclusive except that in the track section 45 oppositely facing recessed seats 46 and 41 are formed for cooperating with portions of jaws 48 and 48 respectively to form the said oiisets 42 and 43.

The jaws 48 and 49 are mounted for sliding movement toward and from each other and toward and' from the guide track 45, said jaws being so mounted on a bed plate 50 which corresponds to the bed plate I4 in the structure shown in Figures 1 to 5 inclusive. The track 45 is also suitably mounted on said bed plate in fixed position thereon.

The track 45 has associated therewith upwardly extending flange pieces 5|, 52, 53, and 54, said flange pieces being suitably rigidly secured to the sections and held therewith in a fixed relation to the bed plate 50 on which the jaws are forced outwardly by the respective springs are slidably m unte 10 so as to cause the key-like heads 15 of the pins The jaws 48 and 49 are substantially alined to remain in the position shown in Figure 11 relaand they each have projections designed to cotive to the track 45 and the coil ofisets 42' and operate with the seats 41 and 46 respectively of 43 formed in the springs 4| and 40 respectively the track 45 to form the relative staggered offthereby to hold said coil offsets in said position sets 42 and 43 in the coils 4| and 40 respecrelative to thetrack while the helix 44 is threaded tively. around said coil offset portions 42 and 43. In

The projection 56 of the jaw 49 has an end Figure 11 the jaws are shown in their innermost portion 51 formed to cooperate with the shoulder position and before the same are retracted. In

or seat 45 in the track 45 to form the offset 42. Figure 6 the jaws are shown retracted to such Said projection 56 is also so shaped as to coopan extent that the offset-forming ends such as erate with an ear or lug 58 formed on the guide 51 thereof are disposed approximately in regis track flange 52 and with a suitably shaped retration with the inner walls of the flanges of cessed portion 59 of the guide track flange elethe guide track 45. Hence said offset-forming ment 54 to form the end portions or'legs BI] and ends of the jaws do not interfere with the free 6| of the offset 46in the coil; i passage of the helix and the winding thereof The projection 55 of the jaw 48 is similarly around the spring coil offsets. The heads 15 of formed to cooperate with the recessed seat or the holding pins are, however, suitably grooved shoulder 47 in the track Ill and with an car as indicatedat 11 to form, in effect, continuations portion 52 formed on the flange element 53 and oftlie helical guide grooves of the track 45 to a suitably recessed seat 63 formed in the adjathereby permit the winding of the helix around cent en portion of the flange-element 5|. The the offset portions notwithstanding the holding projecting portions 55 and 56 each have upper thereof in place on the track by said holding portions 64 and 85 respectively which extend pins. over the respectively engaged spring coil por- After the helix has been threaded for the entire tions to move the same downwardly to the relength of the spring rows to be assembledj the. spective seats 41 and 46 in the track 45 and to jaws 48 and 49 are further retracted so as to hold the same in cooperative relation to s i withdraw the holding pins 68 from engagement seats while the respect 3 Projections enter with the coil offsets; The helically connected said recessed seats to form the offsets in the coil springs may thenbe elevated and moved latspring coils. v erally over the jaws preparatory to the next coil When the springs are initially delivered to the onset-forming and helical-tying operation. In jaws, they may not immediately rest on the track Figure 6, there is illustrated an arm 18 having 45 but the inclined cam-like surfaces 66 and B a double hooked end portion 19 which is adapted of said projecting portions 64 and 65 resp ctiv ly to be moved upwardly to raisethe connected coils will serve-to cam said coil portions downwardly above the top of the jaws and then moved laterinto operative relation to the oifset forming porally to feed the connected spring row laterally tions such as 57 of the jaws and the track seats substantially as shown in the said Gail patent and in my said co-pending application. Th jaw and 41.

Each of the jaws 48 and 49 have moun e 49 is suitably recessed as indicated at 80 and the therein a spring-coil ho d g pin such as 68. flange element 54 is suitably recessed as shown Said pin 63 extends length-wise of the resD at 8| to permit the required endwise movement tive jaws and about centrally of the respec of the hooked member 18 into operative position I offset forming projections 55 and 56 therein as 45 relative to the coil. Similarly .the jaw I3 is best shown in Figure 6. grooved as indicated at 82 to permit the opera- Each sp g-coil holding pin 68 is longit d tion of a spring construction lifting and feeding nally slidably mounted in a suitable bore 69 prodevice such as 18, also in keeping with said patvided in the jaw, a coil spring 10 being provided ent and co-pending application. around a portion 013 the p f urging Sa d p When the springs 4ll and 4| (Figure 6) are diso m v outwardly of the respective ends of the r placed from the track 45 and released from the jaw protections and 56. The springs 0 are respective jaw ends, the inherent resiliency of fairly stout springs and under compression bethe wire of which the springs are formed causes tween the enlarged outer end portion 1| of each the offset portions 42 and 43 to at least paritally pin and the bottom shoulder T2 of the recess 59. return to their initially curved condition, the re- Movement of the respectiv p 53 under the sult being that said offsets will appear approxifiuence of th sp 10 y be conveniently mately as shown at the right hand end of Figv limited by providing the inner end portion 13 of ure 6. IAS there shown, the offsets 42 and 43 are each pin with a cross pin 14 extending diametrimore or less curved and approximate a condically through the pin 13. Limited movement of U tion in which theywill have engagement with th pin 68 is permitted by providing an opening opposed turns of the helix 44 whereby undesir- |'|5 in the jaw for the pin I4, said opening I15 able shifting of the ofifset portions 42 and 43 being of such size asto permit the desired extent within the helix will be resisted. It is not, howof movement of the pin 68 relative to the'jaw. ever, important that the ofisets 42 and 43 re- The outer end of the pin wardly extending lug or key-like portion 15 posed portions of the helix since it is quite feasible formed integral therewith and slidably mounted to produce the ofisets of such length that the in a guideway 16 shaped to slidably receive said end legs 85 and 86 thereof will have firm engagekey-like portion 15. ment with certain turns of the helix-44 substan- 68 has a radially upd5 sume sufficient curvature to actually engage op- After the jaws 48 and 49 have been moved'to 70 tially as indicated at 81. The helix may in effect their limited movement toward the track 45 and be slightly compressed between the leg 85 and 85 have completed the formation of the offsets 42 of each of said offsets to thereby insure the mainand 43 in the spring coils, the jaws are retracted tenance of contact between the helix and offsets slightly. When the jaws are retracted to the limto prevent undesirable relative movement beited extent indicated, the spring-pressed pins 68 tween said parts. It may be noted that as shown in Figure 6 the oflfsets l2 and 43 will remain in substantially straight condition when heldin the track seats 48 and 41 by the holding elements 15, this being due to-the presence or the respective jaw projections between the legs 85 and 86 which serve to hold the latter in substantially fixed position between the respectively adjacent ends of the side flange element 52 and 54 or ii and 53.

For the same purpose the track 20 is'recessed as shown at 83 and the jaw l2 recessed as shown at 84 in the construction shown in Figures 1 to 5 inclusive.

It will be understood that although there has been illustrated and described in this application only one set of jaws for acting on juxtaposedfli coil portions of springs in adjacent rows, that in a, full sized spring assembling machine, such as shown in the Gail patent and in my said copending application, a plurality of sets of jaws such as shown and described are contemplated, there being one set of jaws for each spring in the rows of springs to be united. Furthermore, in respect of the arrangement-shown in Figures 1 to 501? this application, the cam operating means for actuating the jaws of the said patent and co-pending application may be employed or that other arrangements may be employed if desired or found necessary to supply the force required to form the offsets in the springs. In respect of the actuation of the jaws in the form of construction represented in Figures 6 to 11 inclusive,

the cam operating means shown in said patent and co-pending application typify one form of operating mechanism, although it will be apparent that some slight modification of the cam will be required to produce the two-step retracting movement of the jaws, the operating cam mechanism may in general be of the same character as shown in said patent and, co-pending application. The required cam modification involves merely proper designing of the cam to produce the required movement and, being an ordinary mechanical expedient, is not herein illustrated.

Apparatus embodying the jaw construction herein described will have conventional coil of the coils and winding a helix around said oilset and the juxtaposed coil portion of the other spring while said terminal coils are held in said predetermined juxtaposition.

2. The method of tying together a pair of coil springs, which consists in positioning the springs in predetermined juxtaposition, the springs having normal circular or spirally formed terminal coils, forming an offset in one of the coils so positioned, and, while the springs remain in said juxtaposition, winding a helix around the offset so formed and around a coil portion of the other of said pair of springs.

3. The method of tying together a pair of coil springs, which consists in providing a pair of such springs having normal circular or spirally formed terminal coils, positioning the springs with their terminal coils in predetermined juxtaposition, then forming complementary offsets in the juxtaposed terminal coils of the springs, and, while the springs remain in said juxtaposition, winding a helix around said complementary offset portions.

4. The method of making inner spring construction units which consists in assembling into predetermined juxtaposition a pair of coil springs having normally circular or spirally formed terminal coils, and then, while maintaining the springs so assembled, forming oppositely projecting oflsets in said terminal coils and threading a helical wire around the, ,offsets so formed,

' thereby to tie the springs together.

springs delivered to it, will operate on said springs to form the offsets desired, effect tying of the springs together by means of helicals and will advance the tied-together spring rows to permit the delivery of another row 01' springs into juxtaposition with the trailing end of the a previously united spring rows. The mechanism herein described thus serves to completely eliminate the independent handling and forming of same being construed'as broadly as possible consistent with the state of the art.

I claim: x l. The method of making inner spring con- 5. The method of making inner spring construction units which consists in assembling into predeterminedjuxtaposition a pair of coil springs having normally circular or spirally formed terminal coils, and then, while maintaining the springs so assembled, forming relatively staggered oppositely projecting offsets in said terminal coils and threading a helical wire successively around the oilsets so formed, thereby to tiesaid coil springs together.

- EDWARD E. WOLLER.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 2,026,276 Erickson Dec. 31, 1935 1,920,862 Heuer Aug. 1, 1933 1,930,715 Heuer Oct. 17, 1933 2,012,904 Bowersox Aug. 27, 1935 1,812,611 ,Stackhouse June 30, 1931 1,756,434 Owen Apr. 29, 1930 1,705,821 Lehmann et a1 Mar. 19, 1929 1,922,002 Kan Aug. 8, 1933 Certificate of Correction Patent No. 2,420,512 May 13, 1947 EDWARD E. WOLLER It is hereby certified that error appears in the above numbered patent requiring correction as follows:

In the heading to the printed specification, lines 8 and 9, for Patent No. 2,388,106, dated October 80, 1945 read Patent No. 2,420,511, dated May 13, 191/); and that the said Letters Patent should be read as corrected above, so that the same may conform to the record of the case in the Patent Oflice.

Signed and sealed this 10th day of April, A. D. 1951.

THOMAS F. MURPHY,

Assistant Gammz'ssz'oner of Patents. 

